HEV, PHEV, BEV Test Standard Validation

2011 DOE Hydrogen Program and Vehicle Technologies Annual Merit Review

May 10, 2011

Michael DuobaArgonne National Laboratory

Sponsored by Lee Slezak

This presentation does not contain any proprietary, confidential, or otherwise restricted information

Project ID # VSS052

Continuing effort since 2006 Focus on EV Testing (SAE J1634)

– J1634 begun in 2009– J1634 completion in 2011 YE– J1634: 90% Complete

Aid in SAE 2711 MD/HD Procedure – Revision process started

Barriers addressed– Address codes and standards

needed to enable wide-spread adoption of electric-drive transportation technologies

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$400k in FY11 Effort leverages Advanced

Powertrain Research Facility staff and test vehicles

Timeline

Budget

Barriers

ANL staff is Co-Chair of J1634— Task Force includes experts from

EPA, Toyota, Honda, Ford, Chrysler, GM, Nissan, JARI, Mitsubishi, CARB

AVTA, OEMs and Suppliers, Customers, X-Prize, Tesla, BMW

Partners

Standards Overview

Standards Development Activities in FY11

J1634: BEV dynamometer test standards (consumption and range)

– Rewrite for modern BEVs

J1715: HEV Terminology (“to EREV or not to EREV”)

– Updated from version several years ago

J2951: Drive Quality Evaluation for Chassis Dynamometer Testing

– New standard to explain fuel economy variations

ISO 23274-2: PHEV dyno testing in depleting mode

– 23274-1 is testing in the sustaining mode

J2711: Dyno testing of MD/HD vehicles including HEV

– Committee just formed. Lead roles still being considered

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J1634 Relevance: Industry and Regulatory Agencies will Incorporate this Updated BEV Test Procedure

Vehicle economy / range is defined according to test procedures

OEMs recognized immediately existing J1634 is not suitable for >100mi EVs

Relevance: Mass produced BEVs will use the J1634 Task Force methods

Relevance: MD and HD BEVs can also use same general technique

Define Vehicle

Build Prototypes

TEST (J1634)

Production Run

Certification/Labeling (J1634)

Validate

OEM DevelopmentEPA, CARB,

R&D

J1634 Approach: Provide Data, Direction, Validation, Document Development Jeff Glodich (Ford) and Mike Duoba co-chair J1634 task force

Objective: – Develop new, shorter test methods that accomplish the same objectives as existing

J1634 procedure

– Validate methods with actual BEV dynamometer testing

– Leverage on-going/previous testing at ANL

Approach:

Gather Ideas and Methods

Compile Test Options to Investigate

J1634 Participants Try Methods and

Report

Analyze Results, Make Procedure

Adjustments

Validate Final “Short-Cut”

Method

Describe Procedure in SAE Standard J1634

Ballot

2010 Merit Review

2011 Merit Review

FY10

FY11

J1634 Problem Statement:

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“Death by Urban”

250mi = 17+ hours of testing, no interruptions allowed

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J1634 Approach: ANL Procedure Development

Test Product: Find Efficiency (AC Wh/mi) and Range (mi) for any given cycle

Constraint: Short-cut must provide repeatable results consistent with the longJ1634 method

Short-Cut Method in General:1. Find battery capacity (on-dyno)

2. Run test cycles (UDDS, HWY, US06) to find Efficiency

3. Use consumption and capacity data to find Range

ANL tools and vehicles– FY10: EV-optimized 2WD dyno facility

– FY10: OEM BEVs from companies and private owners

– FY10: ANL-built “TTR” prototype PHEV platform run in EV mode

– FY10: Battery HIL testing isolating battery to validate repeatability, response of battery,charger, and BMS

– FY11: Several X-Prize BEVs

– FY11: Tier 1 Supplier BEV

J1634 Technical Accomplishment: ANL Staff Provided Key Inputs to Test Concept

Committee decided to adopt ANL concept (internally called “Super Short Cut”) for most time-efficient test procedure

– Run UDDS, HWY, US06 as if it were a conventional vehicle, then recharge

– Use method similar to J1711 method to calculate AC energy based upon DC dyno measurements

Helped define equations and terminology

Definitions made to be compatible with J1711 and ISO standards

J1634 Technical Accomplishment: Argonne Tested X-Prize Electric Vehicles

ANL developed test procedure - some concepts compared with the draft J1634 at that time

ANL had to validate “full charge” to avoid errors in AC kWh/mi data (and possible gaming)

Collecting data from a diverse set of advanced batteries and BMS systems provided guidance for J1634 charge validation rule

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BEV Test Procedure (J1634) Project Summary

Objective: Develop test procedure methods that are practical for today’s >100mi range battery electric vehicles

Relevance: Direction of J1634 will likely be used throughout industry and government agencies for quantifying BEV performance on a dynamometer

Accomplishments: – Using experience from ANL’s successful benchmarking program and J1711

leadership, many key features of the new test concepts were ANL contributions

– Numerous testing projects supported development and validation of new test concepts for wide-spread collaboration

Next Steps: Document revisions underway for modifications related to new testing methods

Conclusion: Many contributions of committee members make this program a truly group effort to develop a suitable test procedure for the next generation of electric vehicles

Challenges for J1715: New Technology Needs New, Consensus Terminology

SAE Technical Information Report J1715 “Hybrid Electric Vehicle (HEV) & Electric Vehicle (EV) Terminology” was first published in 2008

Discussions in media, advertising jargon and in technical papers offered confusing and sometimes conflicting terminology

– Micro-hybrid

– Strong hybrid

– Plug-in hybrid

– Extended-Range Electric Vehicle (E-REV)

– Range-Extended Electric Vehicle (ReEV)

Decided early on that “strong, full, mild” terms would not be part of SAE hybrid terminology

Much discussion on whether “EREV” would be an SAE term– Is an EREV a PHEV?

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J1715 Accomplishment: Fine-Tuning Terminology

ANL proposed vehicle terminology map

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J2951: Develop Metrics to Help Explain Test-to-Test Variation Due to Driver Variability

Started: Aug 2010. Finish: Summer 2011?

Prescribed certification tolerances leave room for significant fuel economy variation

Existing speed tolerance is not enough information to explain varied results

Data has shown that higher fuel consumption results correlate with higher driven dyno energy

Results from hybrids are notoriously “noisy”

ANL has been using enhanced driver performance metrics for 10 years

ANL is providing conceptual input and data to committee

Accomplishments: Equations at right are represented in 80% finished draft.

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Driven Energy vs Cycle Energy

Excessive Transients

Number of peak accels

Still under development

Drive cycle

Test

ISO 23274-2 SupportHarmonization of PHEV Procedures

ISO Standards require many years to develop

Attended meetings since 2007– Tokyo, Paris, Berlin, Chicago, Paris

Most difficult problem is defining end of charge-depleting operation

ISO committee looking to a very precise method, but perhaps not always practical for routine testing

Settled on a method that is not in conflict with J1711

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J2711: Now UnderwayMD/HD Vehicle Testing

Standard is just beginning revision process (Revision of 2002 document)

ANL is taking a leadership role to ensure best-practices from light-duty testing are implemented when appropriate

Very challenging, it likely covers:– Hardware-in-the-loop methods

– Dynamometer methods

– On-road methods

Properly dealing with charge-balance, SOC issues will take some development and validation

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Collaborations and Coordination with Other Institutions

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SAE Task Force Membership• OEMs• Suppliers• Regulators• National Labs

APRF

DOE Evaluation Activities• National lab analysis• Technology evaluation

AVTA (Advanced Vehicle Testing activities)Baseline dynamometer testing of vehicles ®

Summary of FY11 Standards Development Activities

On-going standards for 2011

J1634: BEV dynamometer test standards (consumption and range)

– Rewrite for modern BEVs

J1715: HEV Terminology (“to EREV or not to EREV”)

– Updated from version several years ago

J2951: Drive Quality Evaluation for Chassis Dynamometer Testing

– New standard to explain fuel economy variations

ISO 23274-2: PHEV dyno testing in depleting mode

– 23274-1 is testing in the sustaining mode

J2711: Dyno testing of MD/HD vehicles including HEV

– Committee just formed. Lead roles still being considered

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ANL is continuing to leverage many years of vehicle testing success to help develop procedures that are robust, practical, and unbiased